US5465777A - Contact pouring - Google Patents
Contact pouring Download PDFInfo
- Publication number
- US5465777A US5465777A US08/245,705 US24570594A US5465777A US 5465777 A US5465777 A US 5465777A US 24570594 A US24570594 A US 24570594A US 5465777 A US5465777 A US 5465777A
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- United States
- Prior art keywords
- pouring vessel
- nozzle
- pouring
- mold
- vessel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
Definitions
- the molten metal After the molten metal exits the pressure pouring vessel, it is generally directed into a pouring basin which is cut atop the mold.
- the pouring basin serves no purpose other than to act as an open end of a funnel to facilitate the pouring of all the metal into the mold.
- This pouring basin is fitted or connected to a sprue or canal which directs the molten metal into a casting cavity within the mold.
- the sprue is typically tapered to control the flow of the molten metal into the mold. Since the casting cavity is generally filled from the bottom, the height difference between the molten metal level in the casting cavity and the top of the molten metal in the pouring basin determines the rate at which the mold is filled.
- the casting yield of a mold is defined by the casting weight divided by the total mold pour weight, it is apparent that if the pouring basin can be eliminated altogether, the casting yield can be significantly increased.
- a contact pouring vessel and method for pouring molten metal directly into a mold is disclosed. This is basically achieved by elevating a pouring vessel which contains the molten metal. Positioning the mold under a nozzle within the pouring vessel. Lowering the pouring vessel so that the nozzle is flush with the mold. Filling the mold with the molten metal and again raising the pouring vessel. Thereafter, automatically cleaning the nozzle with a rotating cutter.
- a pouring vessel for holding the molten metal in a molten state.
- a nozzle is contained exterior to the pouring vessel and has an orifice through which the molten metal can flow.
- a stopper rod is used to seal the orifice in the nozzle to prevent the molten metal from exiting the pouring vessel until the stopper rod is raised.
- a rotating cutter is used to clean the nozzle each time a mold is filled, thereby preventing an unwanted buildup on the nozzle.
- Four hydraulic cylinders and a hydraulic system are used to raise and lower the pouring vessel. The pouring vessel is raised to accommodate the positioning of the mold adjacent the nozzle, while the pouring vessel is lowered to position the nozzle flush with the top of the mold.
- FIG. 1A is a partial cross-sectional view of one preferred embodiment of the present invention in a fully elevated position
- FIG. 2B is cross-sectional view of another embodiment of the nozzle cleaning device
- FIG. 3 is a cross-sectional view of a vessel raising and lowering system of the present invention taken along the line 3--3 of FIG. 1A;
- FIG. 4 is a schematic block diagram of a hydraulic system of the present invention.
- FIG. 1A a cross-sectional view of one preferred embodiment of a contact pouring vessel 10, is shown in its fully elevated position.
- the contact pouring vessel 10 contains molten metal 12 which is contained within an outer metal housing skin 14 and a thick refractory layer 16.
- the molten metal 12 enters the contact pouring vessel 10 through a fill spout 18 located adjacent to a fill chamber 20.
- the molten metal 12 is kept heated and molten by an induction furnace 22 located at the lower portion of the contact pouring vessel 10.
- the induction furnace 22 includes a coil assembly 24 which essentially performs the heating function of the induction furnace 22 as the molten metal 12 flows around a molten metal loop 26.
- the contact pouring vessel 10 is equipped with a pouring launder 28 which is fitted with a stopper rod 30.
- the stopper rod 30 is snugly seated within an orifice 32 of a nozzle 34 to prevent the molten metal 12 from exiting the pouring launder 28 until the stopper rod 30 is raised.
- the stopper rod 30 is raised or lowered approximately two (2) inches via a lift mechanism 36 which is preferable a hydraulic cylinder 38.
- the molten metal 12 is evacuated from the contact pouring vessel 10 into the pouring launder 28 by means of applying pressure 40 atop the molten metal bath 12 in an intermediate chamber 42.
- the level of the molten metal 12 in the pouring launder 28 is maintained constant by a level sensing system 44 as the pressure 40 is applied to the intermediate chamber 42.
- the level sensing system 44 is preferably a Selcom Model 2005-554 reflective laser system which utilizes lasers (not shown) as a measuring mechanism.
- the contact pouring vessel 10 is quickly lowered approximately four inches by means of four (4) hydraulic cylinders 50. This allows the nozzle 34 to seat firmly and flush atop the mold 46, which is preferably a sand mold 46. Thereafter, when the stopper rod 30 is raised by the lift mechanism 36, the molten metal 12 flows from the pouring launder 28 out the orifice 32 of the nozzle 34. The molten metal 12 flows into a sprue or canal 52 to fill mold cavities 54.
- the mold cavities 54 are filled by the molten metal 12 in the pouring launder 28 as long as the stopper rod 30 is in its up position. The longer the stopper rod 30 is left in its up position, the longer the molten metal 12 flows into the mold 46.
- the pour is completed in about 10 to 12 seconds and the stopper rod 30 is then lowered into nozzle 34. Thereafter, the contact pouring vessel 10 is elevated to its full up position, shown in FIG. 1A, by utilizing the hydraulic cylinders 50.
- FIG. 2A there is shown a nozzle cleaning device 56 which is connected to the pouring launder 28 via a support arm 58.
- the nozzle cleaning device 56 is employed to remove and clean sand, solidified iron and slag which tends to buildup on the underside of the nozzle 34, so that the nozzle 34 will seat flush against the mold 46. If the unwanted buildup is not removed, the molten metal 12 will leak between the nozzle 34 and the mold 46, resulting in molten metal 12 flowing out and over the mold 46. If this overflow occurs, the pouring operation typically must be aborted for the mold 46, being filled.
- a cutter 60 is utilized to remove the unwanted buildup.
- the cutter 60 is automatically pivoted into place under the nozzle 34 by a cutter arm 62 utilizing a hydraulic cylinder (not shown).
- the cutter 60 is rotated at about 120 revolutions per minute (RPM) by a hydraulic motor 64 via a sprocket 66 and a chain drive 68.
- the cutter 60 is preferably a standard milling cutter having carbide/high speed steel inserts for teeth 70. It should also be noted that an abrasive grinding disk 71 may be used in place of the cutter 60, shown clearly in FIG. 2B.
- the abrasive grinding disk 71 is about one-quarter (1/4) of an inch thick having a coarse surface comprising aluminum oxide.
- the abrasive grinding disk 71 is rotated about 1000 RPMs.
- the nozzle cleaning device 56 is employed each time a mold 46 is poured to face or clean the build-up on the nozzle 34, thereby truing the relationship between the nozzle 34 and the mold 46.
- a contact pouring lift system 74 is employed, shown clearly in FIG. 3.
- the lift system 74 utilizes the four (4) hydraulic cylinders 50 to raise and lower the contact pouring vessel 10 approximately four (4) inches to allow the positioning and indexing of multiple molds 46 beneath the nozzle 34.
- Four (4) vertical guide bars 76 pass through a base plate 78 to eliminate any horizontal thrust on the hydraulic cylinders 50 and to insure vertical alignment of the contact pouring vessel 10, shown clearly in FIGS. 1A and 1B.
- the hydraulic cylinders 50 and the vertical guide bars 76 are also mounted to a support plate 79.
- the contact pouring vessel 10, which typically weighs about 30,000 pounds, is raised or lowered about four (4) inches in a time span of about two (2) seconds for an average velocity of about two (2) inches per second.
- the pouring launder 28 generally will flex under the heat of the molten metal 12 (i.e., 2700° F.) and the movement of the vessel 10.
- the base plate 78 is fitted with four (4) ball screws 80 located at each corner of the base plate 78 and positioned under the vessel 10.
- Each ball screw 80 is actuated with a servo motor (not shown) to reposition the level of the contact pouring vessel 10 which maintains the bottom of the nozzle 34 parallel with the top of the mold 46.
- a programmable logic controller (not shown) used in conjunction with transducers (not shown) are used to sense the relationship of the nozzle 34 to the mold 46 in order to adjust the ball screws 80 accordingly over time.
- FIG. 4 there is shown a schematic block diagram of a hydraulic system 82 used to control the hydraulic cylinders 50.
- the hydraulic system 82 includes a hydraulic power supply 84.
- the hydraulic power supply 84 includes a fluid reservoir 86 having a fluid meter 88, temperature controls 90 and level controls 92.
- the hydraulic fluid (not shown) in the reservoir 86 is pumped through a double gang pump 94 having a motor 96.
- An additional pump 98 and a motor 100 are also utilized to continuously filter the hydraulic fluid.
- the hydraulic power supply 84 is connected to the hydraulic cylinders 50 via a hydraulic manifold 102, which is essentially a connecting mechanism.
- a regulator valve 104 is connected to the hydraulic manifold 102 to maintain a substantially constant pressure throughout the hydraulic system 82.
- two filters 106 are utilized to ensure that the fluid remains clean from contaminants.
- the proportional control valve 108 is an analog valve which controls the speed of the hydraulic cylinders 50 from a ⁇ 10 volt direct current (VDC) input.
- VDC direct current
- the speed of the hydraulic cylinders 50 are controlled so that when the vessel 10 is lowered, it does not hit the mold 46 abruptly, thereby causing the mold to break which will result in sand filling the sprue 52 or distortion of the mold cavities 54.
- the fluid feeds through four flow dividers 110 which are coupled together mechanically to evenly meter the fluid into each hydraulic cylinder 50. By feeding the hydraulic cylinders 50 evenly, this ensures that the vessel 10 raises and lowers evenly to allow the nozzle 34 to seat flush with the mold 46.
- the fluid then passes through check valves 112 which are activated by solenoids 114 controlled with 120 volt alternating current (VAC) signal.
- VAC 120 volt alternating current
- the check valves 114 are de-energized so that when the vessel 10 reaches its fully elevated position, the valves 112 check so that the vessel 10 will not lower.
- the solenoids 114 are energized to release the fluid checked by the check valves 112.
- the fluid is then returned evenly back through the flow dividers 110. This allows the vessel 10 to be lowered evenly, while the proportional control valve 108 controls the speed.
- the proportional control valve 108 controls the speed.
- the contact pouring vessel 10 is first set in its fully elevated position, as shown clearly in FIG. 1A.
- a mold 46 on the conveyer belt 48 is then indexed into place beneath the nozzle 34.
- the contact pouring vessel 10 is then controllable lowered with the hydraulic cylinders 50 so that the nozzle 34 contacts or seats flush against the mold 46, shown clearly in FIG. 1B.
- the stopper rod 30 is then raised with the lift mechanism 34 to release the molten metal 12 into the sprue 52 and the mold cavities 54.
- the pressure 40 ensures that there is molten metal 12 in the pouring launder 28 and assists in the release of the molten metal 12. Once the mold cavities 54 are filled, the stopper rod 30 is lowered to prohibit further release of the molten metal 12.
- the pouring vessel 10 is then elevated, as shown in FIG. 1A, to allow the next mold 46 on the conveyer belt 48 to be indexed into place, in addition to allowing the nozzle 34 to be cleaned with the nozzle cleaning device 56.
- the nozzle cleaning device 56 removes unwanted buildup on the nozzle 34 such as sand, slag and solidified iron.
- the nozzle cleaning device 56 is then pivoted away from the nozzle 34 so that the pouring operation on the next mold 46 can begin.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
Description
Claims (23)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US08/245,705 US5465777A (en) | 1994-05-18 | 1994-05-18 | Contact pouring |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US08/245,705 US5465777A (en) | 1994-05-18 | 1994-05-18 | Contact pouring |
Publications (1)
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US5465777A true US5465777A (en) | 1995-11-14 |
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US08/245,705 Expired - Fee Related US5465777A (en) | 1994-05-18 | 1994-05-18 | Contact pouring |
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Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE19925945A1 (en) * | 1999-06-08 | 2000-12-14 | Abb Patent Gmbh | Casting device has a refractory-lined boiler equipped with a gutter into which the outlet funnel feeds |
US6453978B1 (en) * | 1999-05-03 | 2002-09-24 | Heinrich Wagner Sinto Maschinenfabrik Gmbh | Method and an apparatus for filling of molds with liquidy metals |
US6588684B1 (en) * | 1998-12-18 | 2003-07-08 | Wesley A Staples | Fluid injector for tank cleaning |
US6591895B2 (en) * | 2000-09-22 | 2003-07-15 | Inductotherm Corp. | Molten metal pouring with retractable shield for pour control |
US20090218375A1 (en) * | 2008-03-03 | 2009-09-03 | Doyle Ray Ledbetter | Close proximity pouring device |
CN103521744A (en) * | 2013-10-14 | 2014-01-22 | 南昌大学 | Semisolid slurry receiving and injecting device |
CN103521745A (en) * | 2013-10-14 | 2014-01-22 | 南昌大学 | Molten metal taking-injecting device |
WO2016128481A1 (en) * | 2015-02-10 | 2016-08-18 | Otto Junker Gmbh | Pouring device for pouring a metal melt and method for operating such a pouring device |
CN108856685A (en) * | 2018-06-29 | 2018-11-23 | 无锡范尼韦尔工程有限公司 | A kind of automatic turning running gate system producing large-scale ocean ship turbine |
PL443671A1 (en) * | 2023-02-01 | 2024-08-05 | Politechnika Śląska | Attachment for contact pouring |
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Cited By (14)
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